Polyaspartic Coating Technology Improving Productivity without Sacrificing Performance
- Slides: 38
Polyaspartic Coating Technology – Improving Productivity without Sacrificing Performance Todd Williams (presenter) Ahren Olson covestro. com © Covestro LLC 2016
Learning Objectives § Polyaspartic coatings • History • Basic chemistry • Value proposition § Coating applications • Direct-to-metal (blasted steel) • 2 -Coat systems (over organic zinc primer) § Formulating polyaspartics • Pot life issues • Next generation of polyaspartic hardeners © Covestro LLC 2016
Evolution of coatings binders at Covestro (Bayer) Polyaspartics is next generation of protective coatings Bayer synthesizes chlorinated rubber binders 1970 s – 1990 s 1940 s 1960 s Bayer invents aromatic polyurethane coatings © Covestro LLC 2016 Bayer invents aliphatic polyurethane topcoats Bayer invents polyaspartics 2000 s – today 1990 s – today Bayer invents waterborne polyurethanes
Polyaspartics Coatings Evolution - Over 10 Years Proven Performance Industrial Maintenance 2 nd Generation Polyaspartic Coatings Commercialized Concrete Floor Application Polyaspartic Resin Invented 1992 1998 © Covestro LLC 2016 Industrial Maintenance Polyaspartic Coatings Commercialized 2000 2002 2003 2 nd Generation Polyaspartics Invented 2011 2013
Polyaspartics differ from polyurethanes in that no tin catalyst is required – thick films R R’ N C O + R Water Catalyst H N O R R R’ N C N X H Isocyanate Aspartate X Aliphatic Urea O + R N C O R’ OH R N Tin Catalyst Isocyanate Polyol © Covestro LLC 2016 C OR’ H Urethane Also catalyzes water / isocyanate reaction yielding CO 2 gas and limits film thickness
Polyaspartic Resins Polyaspartic Structure © Covestro LLC 2016 Viscosity (c. Ps) Pot Life (min) 100 <5 1000 20 1200 480
Humidity catalyzes polyaspartic reaction – dry times effected by environmental conditions 120 Reaction Conversion (%) Hard Dry 100% Humidity 80 60 40 20 0% Humidity 0 0 10 20 30 40 Time (min) © Covestro LLC 2016 50 60 70
Hard dry time vs. humidity – only slight effect since water is catalytic 2 Hard dry time (hours) 1. 8 1. 6 1. 4 1. 2 1 HDI Trimer 0. 8 HDI / IPDI Crosslinker 0. 6 0. 4 0. 2 0 0 20 40 60 80 100 % RH § For 0. 8 hour hard dry time at 50% relative humidity v 1 hour at 30% relative humidity v 0. 3 hour at 95% relative humidity © Covestro LLC 2016
Typical Polyaspartics Coatings Applications Floors Gel Coats Polyaspartic Coatings General Industrial © Covestro LLC 2016 Protective
Value Proposition: improved productivity lowering overall cost by reducing number of layers and cure time Polyaspartic Topcoat Epoxy Intermediate Polyurethane Topcoat Standard for Moderate Corrosive Environment (C 3 – Rural / Inland) Zinc Rich Primer Epoxy Intermediate Polyurethane Topcoat Standard for Severe Corrosive Environment (C 4/C 5 - Coastal / Industrial) Direct-to-Metal Polyaspartic provides equivalent performance Zinc Rich Primer Polyaspartic Topcoat Polyaspartic 2 -coat provides equivalent performance © Covestro LLC 2016
Modern DTM Industrial Maintenance Coatings Advances in DTM one-coat solutions § Equivalent performance to multi-coat systems § Increases productivity and reduces complexity § Advantages for both shop and field maintenance painting Polyurethane Topcoat Epoxy Primer © Covestro LLC 2016 DTM Epoxy, Polysiloxane, Polyaspartic, Polyurethane
Diffusion of Water / Ions in Coatings is Proportional to Film Thickness 2 Ions Permeate to Substrate § Driven by osmotic forces and polymer free volume § Saturation time proportional to the thickness 2 § ISO 12944 recommends minimum film builds for durability © Covestro LLC 2016 H 2 O + Cl. D Where t= saturation time, L = thickness, and D = diffusivity rate
Application and physical property advantages of polyaspartic coatings Application Ø Fast cure with hours of potlife Ø Low VOC (<250 g/L no exempt solvents) Ø No blistering at high film builds Ø No blushing / sweat-in time Physical Properties Ø High initial gloss Ø Easy to apply Ø Color and gloss retention Ø Excellent corrosion resistance © Covestro LLC 2016
Polyaspartic coatings can be used anywhere a traditional epoxy / urethane system is used – atmospheric service only Stadiums Oil and Gas Piping Storage Tanks Wind Turbine Towers © Covestro LLC 2016 Safety Colors Frac Tanks
Increasing Painting Throughput Time savings of 8 hours by using 2 -coat polyaspartic Epoxy Zinc Primer Two-Coat 1 Epoxy Intermediate Polyurethane Polyaspartic 2 Total Hours to Hard Dry 3 Three-Coat 1 4 6 Total Hours to Hard Dry 11 © Covestro LLC 2016
Shorter cure times = less blast media pickup 2 hr cure 6 hr cure Polysiloxane © Covestro LLC 2016 Polyaspartic Polyurethane
Low Temperature Curing – polyaspartic cures rapidly at low temperature – moisture catalyst not reagent Pendulum Hardness vs Cure Time (Days) at 50% RH 140 120 Pendulum Hardness (sec) 100 80 60 40 20 0 0 2 4 6 Cure Time (Days) © Covestro LLC 2016 8 10 12 Polyaspartic 75 F Polyester Urerthane 75 F Polyaspartic 40 F Epoxy 75 F Epoxy 40 F Polyester urethane 40 F
QUV-A Weatherability Polyaspartics comparable to industrial maintenance polyurethane 100% 90% 80% Gloss Retention 70% DTM Epoxy 1 60% DTM Epoxy 2 Polysiloxane 50% Polyaspartic 1 40% Polyaspartic 2 Polyaspartic 3 30% Epoxy / Polyurethane 20% 10% 0% 0 200 400 600 800 1000 1200 Hours UV-A Exposure © Covestro LLC 2016 1400 1600 1800 2000
DTM polyaspartics have superior corrosion resistance 1680 hours prohesion Polysiloxane Polyaspartic © Covestro LLC 2016 1000 hours salt fog
DTM - similar physical properties to epoxy / urethane in one coat Test Polyaspartic Epoxy / Urethane Polysiloxane % elongation 27 20 0 Direct impact resistance (in-lb) 100 20 20 Wet adhesion 5 A 5 A 5 A Dry adhesion 5 A 5 A 5 A Hard dry (hr) 2 8 6. 5 Salt fog scribe creep @ 1000 hours (mm) 0. 9 0. 4 2. 4 Prohesion scribe creep @ 1680 hours (mm) 0. 6 Not tested 2. 1 © Covestro LLC 2016
Direct-to-Metal Case History - Railcars 2002 - Freshly painted DTM 2013 - 11 years of service from Gulf Coast to Northeast v Originally painted - 2002 v Less than 1% rusting after 11 years in service v 30% reduction in labor cost vs. epoxy / urethane © Covestro LLC 2016
3 -Coats to 2 -Coats…Does This Really Work? Validated through 3 rd party accelerated testing 2004 - NTPEP (National Transportation Product Evaluation Program) 2006 - FHWA (Federal Highway association) 2008 - CPTP (Cooperative Paint Testing Program) 2014 - NTPEP (National Transportation Product Evaluation Program) 2 -coat system passes ISO 12944 C 5 High performance criteria © Covestro LLC 2016
FHWA study confirms two-coat system as comparable performance to threecoat Coating System Accelerated 5000 Sea Isle City, hours – Scribe Creep NJ – 2 years MCU Zinc / MCU / Aliphatic PU 1. 7 mm 1. 0 mm Epoxy Zinc / Epoxy / Aliphatic PU 1. 4 mm 0. 0 mm IOZ / Epoxy / Aliphatic PU 2. 8 mm 1. 7 mm Epoxy Zinc / Polyaspartic (1) 0. 8 mm 0. 0 mm Epoxy Zinc / Polyaspartic (2) 1. 6 mm 1. 3 mm MCU Zinc / Polyaspartic (1) 3. 3 mm 0. 0 mm MCU Zinc / Polyaspartic (2) 3. 3 mm 1. 5 mm “…two-coat systems performed comparably to the conventional three-coat, zinc-rich primer/epoxy/polyurethane systems…new two-coat, zinc-rich coating systems can replace three-coat systems… At the same time, painting costs and traffic congestion will be reduced…” FHWA - HRT-2006 -006 © Covestro LLC 2016
NTPEP Evaluation of Two-Coat System Against NEPCOAT criteria Test Method Epoxy Zinc Primer Polyaspartic topcoat NEPCOAT Performance Criteria Salt Fog ASTM B 117 5000 hours Blister Conversion = 10 Blister Conversion = 7 Avg Rust Creep @ Scribe 0. 1 mm Avg Rust Creep @ Scribe ≤ 4. 0 mm Max Rust Creep @ Scribe 1. 5 mm Max Rust Creep @ Scribe ≤ 8. 0 mm Blister Conversion = 10 Blister Conversion = 8 Avg Rust Creep @ Scribe 1. 8 mm Avg Rust Creep @ Scribe ≤ 4 mm Max Rust Creep @ Scribe 3. 7 mm Max Rust Creep @ Scribe ≤ 8 mm Avg System ≥ 2800 psi 350 psi (avg) Prohesion ASTM D 5894 5000 hours ASTM D 4541 Tensile Adhesion © Covestro LLC 2016 Source: http: //data. ntpep. org
CPTP Evaluation of Two-Coat System Validates Performance Alberta Transportation and British Columbia Ministry of Transportation Cooperative Paint Testing Program (CPTP) 2008 3015 hours of ASTM D 5894 Cyclic Weathering Primer Midcoat Finish Coat Scribe Undercut Reinforced Inorganic Phenalkamine Zinc Acrylic Polyurethane 1 mm Organic Zinc Acrylic Polyurethane 1 mm Reinforced Inorganic None Zinc Polyaspartic 1. 5 mm Organic Zinc Polyaspartic 1 mm Epoxy Polyamide None O’Donoghue, M. , et. al (2013) Innovative Coating Systems for Steel Bridges: A Review of Developments Journal of Protective Coatings and Linings, January 2013, 34 -52. © Covestro LLC 2016
Two-Coat Case Study - Connecticut I-84 Overpass Eastbound - Polyaspartic 2 -coat 2013 Westbound - Polyurethane 3 -coat 2013 v Originally painted - 2003 v In 2010, 3 rd party inspector reported less than 2% corrosion v Direct savings of $6 / ft 2 and indirect savings of $18 / ft 2 v 30% faster → 24% cost reduction - traffic rerouting, labor Castler B. International Bridge Conference, Engineers Society of Western Pennsylvania, Pittsburgh, PA, June 10, 2003. © Covestro LLC 2016
Formulating Polyaspartics for Protective Applications covestro. com
Formulating Polyaspartics Similar to 2 K SB PU Pot life control Other issues to consider § Fast / slow resin ratio § Flexible isocyanates § Wet pigments § Sag Resistance § Molecular sieves • Thixotrope § Solvent concentration • Solvent evaporation rate § Aldimines § Wet adhesion additives § Isocyanate reactivity/functionality § Tint base effects § Production under inert atmosphere © Covestro LLC 2016
Dissolved Water Reduces Pot Life – Trimer and standard polyaspartic reaction © Covestro LLC 2016
HDI / IPDI Prepolymers nd Crosslinkers – 2 Generation of Polyaspartics covestro. com © Covestro LLC 2016 30
Comparison of IPDI / HDI prepolymer versus traditional HDI trimer crosslinker HDI Trimer • 3000 cps at 100% solids • ~ 21. 8% NCO • Equivalent wt. - 193 g/mol NCO © Covestro LLC 2016 IPDI / HDI Prepolymer • 2000 cps at 86% solids • ~10% NCO • Equivalent wt. - 412 g/mol NCO • Reduced hydantoin -- shrinkage
IPDI / HDI – Crosslinker designed for polyaspartics • • • More robust in high temperature and humidity Increased recoat window from days to months Improved water resistance Improved prohesion Decreased shrinkage © Covestro LLC 2016
IPDI / HDI crosslinker – Reduces drying time sensitivity to humidity Cure Time at Elevated Conditions IPDI / HDI Prepolymer 95˚F / 90% RH 77˚F / 88% RH 72˚F / 50% RH HDI Trimer 0 20 40 Minutes © Covestro LLC 2016 60
IPDI / HDI Prepolymer – Improved cyclic prohesion Inorganic Zinc Primer (3 -4 mils) Polyaspartic Topcoat (6 -9 mils) Trimer IPDI / HDI Prepolymer 7056 hours ASTM D 5894 © Covestro LLC 2016 Organic Zinc Primer (3 -4 mils) Polyaspartic Topcoat (6 -9 mils) Trimer IPDI / HDI Prepolymer 7056 hours ASTM D 5894
HDI / IPDI Prepolymer– Improved Recoat Window 1 year in field recoat in Baytown, TX Organic Zinc Rich Primer Polyaspartic Topcoat Inorganic Zinc Rich Primer Polyaspartic Topcoat Power wash @ 3000 PSI - Adhesion 1000 - 2400 psi © Covestro LLC 2016
Prepolymer reduces shrinkage and increases recoatability § Hydantoin ring is thermodynamically favored product § Leads to shrinkage – especially at high builds (15 -20 mils) § Reduce shrinkage by reducing urea linkages – prepolymer § IPDI increases glass transition slows down hydantoin kinetics © Covestro LLC 2016
Key Takeaways § Polyaspartics are amines with low reactivity § Commercial applications: flooring, industrial maintenance, general industrial and gelcoats § Moisture catalysis § Replace epoxy / polyurethanes in atmospheric conditions in a single, thick coating application layer increasing productivity § Provide excellent corrosion resistance and cure at low temperatures 37 © Covestro LLC 2016
More Information? Contact Todd Williams Todd. Williams@Covestro. com 412 -413 -2167
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